IGBT DC Circuit Breaker for High-Power Fault Interruption
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Solution Overview
Problem
Existing DC circuit breakers are limited in handling high voltages and require component replacement and maintenance after breaking power, making them unsuitable for large applications like drilling rigs and industrial plants.
Innovation Solution
An electronic DC circuit breaker (E-DCB) utilizing an insulated gate bipolar transistor (IGBT) that acts as a fast fuse, connected through optical fibers for control and monitoring, allowing for high power handling and automatic operation without part replacement, with features like galvanic isolation and temperature measurement for self-protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If commercial DC circuit breakers are used, then they can break DC power, but they are limited to handling maximum power of approximately 1.5 kW and require component replacement and maintenance
Solution Approach 1:
The patent replaces mechanical switching components with an IGBT (insulated gate bipolar transistor) based electronic switching system. The IGBT is controlled by a microcontroller that monitors current, voltage, and temperature parameters, enabling the circuit breaker to handle high power (up to 1.5 MW) without mechanical wear. The solid-state electronic components eliminate the need for mechanical replacement and maintenance that characterizes traditional DC circuit breakers.
Solution Approach 2:
The invention changes the operating parameters of the circuit breaker by using an IGBT that can withstand high voltages and currents, unlike conventional mechanical breakers limited to 1.5 kW. The microcontroller dynamically adjusts switching parameters based on real-time monitoring of electrical parameters, enabling adaptive high-power operation while maintaining protection functionality.
2Speed
If mechanical switches are used in DC circuit breakers, then they can switch off currents, but they require component replacement after destroying the switch during short-circuit current limiting
Solution Approach 1:
The patent replaces the mechanical switch with an IGBT-based electronic switch controlled by a microcontroller. The IGBT can switch off currents extremely fast (microsecond range) while being protected by monitoring circuits that detect short-circuit conditions. When a short circuit is detected, the microcontroller immediately turns off the IGBT, preventing the component destruction that occurs with mechanical switches, thereby maintaining both high switching speed and component durability.
Solution Approach 2:
The invention implements a feedback control system where the microcontroller continuously monitors current, voltage, and temperature parameters. When abnormal conditions are detected (such as short-circuit current), the system provides immediate feedback to turn off the IGBT, preventing component destruction. This closed-loop control ensures the switch operates reliably at high speeds without the durability issues of mechanical switches.
3Power
If explosives are used to break the circuit in DC circuit breakers, then they can interrupt current paths, but they require component replacement and system maintenance
Solution Approach 1:
The patent replaces explosive-based circuit interruption with an IGBT-based electronic switching system. The IGBT, controlled by the microcontroller, can interrupt high-power current paths electronically without the need for explosives. This eliminates the complexity of handling, replacing, and maintaining explosive components, while maintaining the ability to handle high power applications.
4Reliability
If traditional fuses are used, then they can interrupt short-circuit current, but they react slower than the IGBT-based E-DCB
Solution Approach 1:
The patent replaces traditional slow-acting fuses with an IGBT-based electronic protection system. The microcontroller continuously monitors current parameters and can detect short-circuit conditions in microseconds, immediately turning off the IGBT to interrupt the fault current. This electronic detection and switching system responds much faster than traditional thermal-magnetic fuses, enhancing protection effectiveness while maintaining system reliability.
Data Source
AI summary
The present invention relates to a device for connecting and breaking DC power comprising an input DC power (DC-In) arranged to be connected to a circuit board (1) and to the collector port (C) of an insulated gate bipolar transistor (IGBT). The insulated gate bipolar transistor (IGBT) is arranged to be connected to the circuit board (1). An output DC power (DC-Out) is arranged to be connected to the emitter port (E) of the insulated gate bipolar transistor (IGBT) and the circuit board (1). The circuit board (1) is arranged to be connected to the gate port (G) of the insulated gate bipolar transistor (IGBT) and the circuit board (1) is designed to monitor predetermined conditions of the input and output DC power (DC-In, DC-Out).